Transcription
Design, Construction and Operationof GaspipelinesEssen, 10. April 2014
2Design, Construction and Operation of Gas PipelinesContent1. Introduction2. Basics / Regulations3. Design4. Construction5. Operation / Safety6. FilmDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
1) Introduction3Gas transmission pipelines (onshore)in GermanyPressure: 16 bar (currently up to 100 bar)Diameters:Temperature:DN 100 (4“) to DN 1400 (56“)-10 C to 60 CLength:few kilometers up toseveral hundred kilometersDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
1) 3 Mon.3–6Mon.BasicDesign6 Mon.RemainingConstruction workDetailedEngineering3–6Mon.12 Mon.3 Mon.9 Mon.12 Mon.End of projectProject startProcedure / Timeschedule of pipeline projects8WeeksUVU I und IINatura 2000 (FFH)LBPbeforeconstr.PFVROVfinal certificate §6.2Commissioning IBNprel. certificate §6.1Acquisition of landWayleavePlan approval§5 AnzeigeProject duration:Project start - Commissioning:about 3,5 YearsProject start - End:about 4,5 Years (incl. Restoration)Notification ofregional planningRightof way / Acquisitionof rightsPrivatrechtlicheVerfahrenDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
2) Basics / Regulations5Legal BasisLawEnWG(Energy Law)RegulationGasHDrLtg-VO(High Pressure Gaspipeline Regulation)Technical RulesDVGW codes of practice,DIN-EN, ISO StandardsIntra Coporate InstructionsOGE Instructions, Guide Lines,Design, Construction an Operation of Gas Pipelines Essen 10.04.2014
2) Basics / Regulations6Energy Industry Act – EnWG (Energy Law)§ 49, Requirements for energy facilities(1) Technical security of energy facilities has to be ensured,compliance with generally accepted standards of technology(2) Compliance with generally accepted standards of technology shall bepresumed when at the plants for the generation, transmission anddistribution of:1. Electricity: the technical rules of the Association of Electrical Engineers,2. Gas: the technical rules of the German Association for Gas and Water(DVGW)are observed.Design, Construction an Operation of Gas Pipelines Essen 10.04.2014
2) Basics / Regulations7High pressure gas pipeline regulation - GasHDrLtg-VO.§ 3 General requirements § 5 Notification and objection of pipeline projects§ 5 (1): Notification to authority at least 8 weeks before start of construction§ 6 Commissioning, prohibition§ 6 (1): Preliminary certificate (after construction, before commissioning)§ 6 (2): Final certificate (After completion of all tests).§ 8 Monitoring.Design, Construction an Operation of Gas Pipelines Essen 10.04.2014
2) Basics / Regulations8DVGW Code of Practice G 463Construction of gas pipelines made of steel pipesfor operation at pressures in excess of 16 bar PlanningDesignConstructionConstruction monitoringCommissioning8
95)3)DesignDesignGas PipelinesMaterial for gas pipelines: up to 10 bar operating pressure: often plastics (DVGW G 472) and steel 10 bar operating pressure: steel (DVGW G 462 and G 463) Coatinginternal lining3 layer PE,PP, EpoxyEpoxy (thickness 0.4-0.5 mm)Different steel gas tubes: Seamless pipes Longitudinally welded pipes or Spiral welded pipesSelection of tubes according to various criteria: Internal pressureMaterialWall thicknessWeldabilityCorrosion protection (active-CP / passive-pipe coating)PriceDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
3) Design10Pipe fittings – Curved partsHorizontal / vertical changes of directionby installing curved partsLong laying radius: Deflection of the welded pipe stringwith permitted elastic deformationSmaller laying radius : Field bend; bends are made of coated steel pipesat construction site with a bending machine(1 - 1,5 per step, e.g. bend DN 500 - R about 25 m) Factory bend, cut bend,production at the factory, heating through induction annealingsubsequent bending.(e.g. factory bend R 10 x D, R 5 x D)andDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
3) Design11Pipe fittings – Other Tee, branches off the main lineSplit teeTeeBarred tee Reducer, installation in case of necessary changes in diameter End Caps Flanges with screws / nuts and seals Insulated joints / insulating flanges Vent Slug catcher Pig trapVent etc.Slug catcherPig trapDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
3) Design12Valves Distinction by type(ball valve, slide valve, gate valve) Distinction by function(tightly – bit worn) Large gas pipelines mostly ball valves(advantage: low construction height& lower weight)Ball valveDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
3) Design13Valve station – StructureDN 1000DVGW Code of Practice G 463:Distance service valve every 10 to 18 kmValve station ConstructionValve station - OperationVenting system in order tobe able to work without gason single line sectionsDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
3) Design14Corrosion control of underground pipingProtectivecurrentdevice SignpostInputsupplyAnode ( )Coke bedReferenceelectrodeCathodic nnection (-)CoatingdefectSampleplateEarthelectrodePipeline with isolatingplastic coatingpassive corrosion protectionBuried steel pipes are protected by a combination ofelectrochemical protection (cathodic protection) andisolating plastic coating (passive corrosion protection).Design, Construction an Operation of Gas Pipelines Essen 10.04.2014
3) Design15Crossings with traffic routes and barriersIn pipeline projects, many traffic routes have to be crossed (streets, railways,rivers, canals, nature reserves and landscape protection areas)Possible crossing techniques Open building method Closed building / trenchless pipe laying:- Impact ramming and thrust boring- Horizontal directional drilling (HDD)- Microtunneling- New methods, for example Direct PipeDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
3) Design16Crossings with traffic routes and barriersOpen building method/ river crossing Total / partial blocking temporarily necessary Railways: installation of so-called temporary bridges for each track,afterwards the trench will be built under it. Crossing of larger rivers / canals by pulling in a culvert Small streams / ditches can be crossed openDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
3) Design17Crossings with traffic routes and barriersTrenchless pipe layingProduct pipe jacking Trenchless laying is done in nominal size of the planned gas pipeline Advantages of a product pipe crossing:- Warranty of safe CP- Simple technical structure- More cost-effective implementationCasing pipe jacking Pipe jacking with a casing pipe Pulling of the product pipe with skids (insulating spacer)Note:Pipe jacking with casing should be avoided if possible (problems with CP)Design, Construction an Operation of Gas Pipelines Essen 10.04.2014
3) Design18Crossings with traffic routes and barriersHorizontal directional drilling (HDD)Crossings possible up to ca 2600 m and DN 14001.2.Basic structure„Rig-Site“3.Basic structure„Pipe-Site“Design, Construction an Operation of Gas Pipelines Essen 10.04.2014
4) Construction19Civil work and pipe constructionBasis for construction execution Plan approval and “free wayleave“ Construction plans and calculation sheets Placed ordersPipe laying Pipeline Method by long pipelines projects:- As long as possible pipeline next to trench- Use of pipe-laying machines (side booms)- Installation services up to about 1,000 m / day Single pipe installation: short pipes, built-up areas and working stripnarrowing- Lowering of individual pipes in trenches with lifting equipment- Pipes are welded together in head access holesDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
4) Construction20Civil work and pipe laying12345Preparation of the routePipe haulingPipe bendingStringing and weldingTesting of welds andcoatings101167891011TrenchingLowering inConstruction surveyBackfillingPressure testRoute recoverySequence of operations by constructionDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
5) Operation / Safety21Quality AssuranceExample: Quality monitoring from the raw material to pipeline operationSteel productionTests: welderand weldsMaterial testing /tensile test(K*s)Weld testing and hydrotesting at workshop(each pipe)Tests: installationcompany andpipe installationStress testing ofcompleted pipelinesMaterialcertificate foreach componentPreliminary andfinal test certificateby TÜV inspectionauthorityDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
5) Operation / Safety22Safety of the pipelineMaterialEnsuring production requirements (pre-production meeting)Control of the raw materialProduction surveillance (Expediting)Acceptance by independent expertsComplete documentation (APZ-acceptance test certificate)Planning and constructionReview of planning documents (§ 5 reports)Certified construction companies (DVGW GW 301)Extensive testing (weld inspection, pressure test)Reduction of laying / welding stresses before use (stress-pressure test)Supervision of work by clientAcceptance by independent experts (§ 6 certificate)Design, Construction an Operation of Gas Pipelines Essen 10.04.2014
5) Operation / Safety23Quality monitoringWalkingsurveyMobilesurveyCathodic protectionmonitoringAerial surveyInvestigationof reportsIntelligent piggingRepairsDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
5) Operation / Safety24Safety of the pipelineOperationCorrosion protectionProtection against external influencesPipeline Integrity Management System (PIMS)MonitoringControl of the coating (intensive measuring)CP controlIntelligent piggingPatrolling, InspectionProtection from approaching construction measuresAssign the route (protective strip)Leak detection by Helicopter (Charm)Design, Construction an Operation of Gas Pipelines Essen 10.04.2014
6) Film25Natural Gas Pipeline Project Loop Sannerz-RimparDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
26Thank you for your attention!Your Questions.Design, Construction an Operation of Gas Pipelines Essen 10.04.2014
27Hyperlinks Slide 3227
4) Construction 28Working strip (Example DN 1000)Top soil storageWorking trackWitdh ofpipe trenchca. 8 mca. 14 mca. 4 mExcavation storageB- and C-Horizontca. 8 mWidth of working stripca. 34 mbackDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
7) Construction 294)Preparation of the route (1)Removal of top soilPreparation of working stripbackDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
4) Construction 30Pipe hauling (2)Pipe storage spacePipe hauling to the routebackDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
7) Construction 314)Pipe bending (3)Bending machinebackDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
4) Construction 32Stringing and welding (4)StringingWeldingbackDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
7) Construction 334)Testing of welds and coatings (5)ISO TestCoating defectbackDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
7) Construction 344)Trenching (6)backDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
4) Construction 35Lowering in (7)backDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
4) Construction 36Backfilling (9)backDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
7) Construction 374)Pressure test (10)Proof- & tightness test(hydrostatic / high-level test:“Stress-test”)backDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
7) Construction 384)Route recovery (11)Application of topsoilRecultivated routeRecultivated route after reseedingDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
39Recultivation of the route and landscapeDuring construction and one year later !!backDesign, Construction an Operation of Gas Pipelines Essen 10.04.2014
Basics / Regulations 3. Design 4. Construction 5. Operation / Safety 6. Film . - New methods, for example Direct Pipe Crossings with traffic routes and barriers . 3) Design . Design, Construction an Operation of Gas Pipelines Essen 10.04.2014 . 16 Total / partial blocking temporarily necessary
